Advanced Flare Stack Monitoring Solutions

A flare stack is a controlled combustion system used to safely dispose of excess hydrocarbon gases that cannot be recovered, processed, or routed elsewhere. It protects personnel and equipment by relieving pressure during routine operations, startups, shutdowns, and upset conditions. Monitoring helps operators confirm operating context, identify abnormal emissions or equipment behavior, and maintain records for environmental and operational review.

Stack monitoring measures or observes emissions and operating conditions associated with an industrial exhaust or flare source. Its purpose is to provide visibility into releases, support environmental compliance, identify deviations from expected operation, and guide corrective action. Continuous, multi-sensor monitoring can add visual, acoustic, and gas-detection context that periodic inspections may not capture between site visits.

Flare stack monitoring combines sensors and analytics to observe conditions continuously. Well Checked’s approach can use high-resolution video for visual context, acoustic sensing for abnormal sound patterns, and long-wave infrared optical gas imaging for methane and VOC detection. Edge computing processes information locally, while AI-assisted validation helps distinguish normal site activity from events that warrant an operator alert or investigation.

Yes. Long-wave infrared optical gas imaging can help detect methane and volatile organic compound anomalies around flare equipment and connected components, day or night. Detection alone is not the same as a final compliance determination; validated events should be investigated according to the operator’s procedures. Multi-sensor context helps reduce false alerts caused by expected process activity or changing site conditions.

Once Zentinal Core™ validates a fugitive-gas event, designated operator teams can receive near-real-time notifications through the Well Checked Dashboard, email, text, and SCADA workflows. Well Checked also provides response-workflow templates, dispatch runbooks, and escalation protocols. These tools support acknowledgement, dispatch, and mitigation within 24 hours, helping teams respond consistently to material events.

Yes. Well Checked’s SCADA integration services are designed to deliver alerts, emissions information, and operational insights within existing control-room workflows. This allows teams to view validated monitoring events alongside their established operational data rather than adopting a separate response process. Integration planning considers the site’s communications, alarm logic, designated recipients, and escalation requirements before deployment.

AI helps establish a site-specific baseline and compare new signals against normal flare and equipment behavior. Zensory.ai™ uses an approximately two-day site-learning cycle to understand expected conditions, while Zentinal Core™ evaluates multiple sensor streams before escalating an anomaly. Alert tuning can also suppress known non-fugitive process events and refine escalation rules as operating baselines evolve.

Continuous monitoring can provide event timing, supporting imagery or sensor context, validation status, and quantified emissions information when applicable. Zentinal IQ™ quantifies emissions after Zentinal Core™ validates an event, helping create defensible records for repair prioritization and reporting. Well Checked structures data to support EPA methane-rule alternative-monitoring submissions, OGMP 2.0 measurement-based reporting, SASB, and TCFD disclosures.